Method of weaving pile carpets and resultant product



March 6, 1951 H. MACKAY ET AL 2,544,338

METHOD OF WEAVING PILE CARPE'IS AND RESULTA'NT PRODUCT Filed June 8,1948 3 Sheets-Sheet l Marh 6, 1951 H. MACKAY ET AL 2,544,338 I FILECARPETS Y METHofi 0F WEAVING AND RESULTANT PRODUCT Filed June 8, 1948 3Sheets-Sheet 2 March 6, 1951 L. H. MACKAY AL METHOD OF WEAVING P CARPETSAND RESULTANT PRODUCT s Shets-Sheet 5 Filed June 8, 1948 7654 waaau mgfatenteci lVlar. 6,

METHOD OF WEAVING PILE cjmrn'rs ANI) RESULTANT PRODUCT Laurence HughMackay and John Mackay, Durham, England Application June 8, 1948, SerialNo. 31,706

In Great Britain November 3, 1947 1'7 Claims.

1 This invention relates to the manufacture of pile carpets, fioor rugsand mats, and has for its object to produce in machine-made carpets andthe like similar carved effects to those obtained in Chinese and otherhand-made carpets, usually by cutting grooves or channels in the pilesurfaces around and in the flowers or other parts of the design, or inthe plain surface of the pile to produce a design.

Whereas in Chinese carpets the cut grooves are usually of V-section, thegrooves or channels hitherto obtained in machine-made carpets haveusually been formed by omitting selected pile loops thereby unavoidablyproducing channels of parallel-sided section. If the machine-madechannels are wide, the pileless back or foundation of the carpet at thebottom of the channels is visible from vertically above, which isobjectionable as detracting from the appearance of the carpet. On theother hand, if the machine-made channels are narrow, they can scarcelybe seen and the carved effect aimed at is largely lost.

The present invention therefore is designed to produce grooves orchannels in the pile surface of a machine-made carpet, rug or mat whichpresent as nearly as possible the effect of V-section grooves orchannels.

In designing a carpet it is usual to start by 2 omit the lifting'of saidpile-forming warp threads where a channel is wanted, a single row ofpile tufts being shown.

Figs. 2, 4, 5 and 6 are lengthwise sections similar to Fig. 1 ofexamples of Wilton type carpets in accordance with our invention; and

Fig. 3 is a diagrammatic plan View of a portion of carpet wherein thepile tufts in the first row represented are disposed as shown in Fig. 2.

Fig. 7 is a lengthwise section showing the application of our inventionto a carpet produced on a double cloth loom.

Fig. 8 shows the same portion of the carpet seen in Fig. 7 afterseparation is completed.

In the drawings, :1 a a and a represent the different pile-forming warpthreads employed, 1), I) represent the stuffer warp threads whichcombine with the unraised pile-forming warp threads to give body to theback or foundation of the carpet. c, 0 represent the chain warp threads,and d, d indicate the weft threads.

In Fig. l, the pile tufts of the carpet are produced by cutting theloops (shown at e formed making a plan of the pattern or squared paper,7

each interstice in the upper surface of the foundation of the carpetbeing represented by one square on the paper. The term interstice isused to define the space in the upper surface of the carpet throughwhich the pile warp threads are drawn to form the pile. A Wilton carpethas a foundation made up of upper and lower weft threads running acrossthe loom and chain warp threads running in pairs. Body is given to thecarpet foundation by stuffer warp threads varying in number according tothe substance desired. In a Wilton carpet therefore each interstice isbounded by two adjacent upper weft threads and two adjacent pairs ofchain Warp threads. It is of course understood that any pile-formingwarp threads not being used for forming pile are carried through thefoundation between the upper and lower weft threads which are boundtogether by the chain warp threads.

In the accompanying diagrammatic drawings,

Fig. 1 is a lengthwise section of a portion of a Wilton type carpethaving a parallel-sided channel formed in the pile surface according toknown practice by using a single frame and stamping the Jacquard cardsto lift the pile-forming warp threads to form pile tufts where requiredand to by drawing single pile-forming warp threads a (shown by brokenlines) which come through each interstice in the foundation, and f is achannel formed by omitting to draw loops of pileforming warp threadsthrough three consecutive interstices. It will be observed that all thepile tufts in this example, including those on each side of the channel,are formed by drawing a single ile-forming thread through eachinterstice, the result being a channel of parallel-sided section thesides of which are, however, too erect when the carpet leaves the loomto produce the desired effect.

The present invention resides in the method of weaving a patterned pilecarpet wherein the pattern is formed by providing the upper surface ofthe carpet foundation with normal pile areas, pile-bare areas, anddenser than normal pile areas, each bare area having along at least partof its boundary a complementary pile area denser than an adjacent pilearea further removed from said pile-bare area, which denser pile area isformed by drawing a thicker mass of pile-forming warp yarn through eachinterstice of said denser pile area than is drawn through eachinterstice of a normal pile area whereby some or all of the followingadvantages are achieved, namely, a more pronounced pattern is obtained,a better carved effect produced, the bare areas are less likely to showthe foundation, the thinning out effect at the edges of the pile-bareareas normally present in machine made carpets which simulate the carvedeffect is avoided and greater wearing qualities secured.

In the manufacture of a carpet having pile tufts and a channel I asrepresented in Figs. 2 and 3, the Jacquard cards are stamped as for twoframes, namely, one frame which provides the main pile-forming warpthreads a v shown in broken lines, and a second frame which provides thepile-forming warp threads a (shown in full lines) which are used todouble or increase the density of the warp threads in the twointerstices immediately adjacent to the edges of the'ch'annel. Thechannel ,1 in the pile is produced when the Jacquard cards (which arestampediin' accordance with the required design) do not cause thelifting of either of the two pile-forming warp threads a or a As thespace in each of said'interstices is; more fully occupied than in theknown example illustrated in Fig. 1 because of the duplication of thepile-forming threads, the threads next the channel are forced orsubsequently caused to fall over as indicatedwhen the pile loopsare'cut. The

falling-over of the unsupported threads adjacent to the channel producesa very similar effect 'to the V-section grooves ofra Chinese carpet by'creating a shadow in the channel and at the same time preventing thepileless back or foundation of the carpet from being seen in said.channel.

We have obtained particularly good effects by arranging the pile-formingloops ascshown in Fig. 4 wherein the loops e formed by the warp threadsa shown in broken lines alternate with the loops e formed by the-"warpthreads a shown in full lines, except when they are combined to doubleor increase the density of the warp threads in the two interstices oneachside" of the channel F,"

but we make no claim to the alternation of the warp threads a and a'except'as constituting" one way of drawing a'thicker mass of threads ofpile-forming yarn throughthe interstices on each side of the channel.'We' also make no claim to'a carpet having channels where doubled or'trebled pile-forming yarn is'used uniformly throughout f This known'practice results equally in the formation of a'carpet similar to thatshown in Fig. l, the only difference being that twice or thrice as manythinner tufts are uniformly'distributed over the surface in place of theusual the pile.

uniform thicker tufts. In a carpet in accordance with our invention, wepurposely vary the thickness of the mass of threads of pile-forming yarnin the tufted areas and make the density of the pile tufts in theinterstices along either or both' margins of each channel greater thannormal density.

Figs. 1 to 4 illustrate examples wherein the pileforming warp threadsare of one color, but, by

employing additional frames operated as herein described, two or morecolors may be used. EX- amples of the use of threads a and a (indicatedin broken and full lines respectively) of one color and threads a and a(indicated in single and double dot and dash lines respectively) ofanother color are shown in Figs. 5 and 6, the double warp threads in thetwo interstices on each side of the channel f being obtained as in theexample shown in Figs. 2 and 3 and in' Fig. 4, respectively.

Carpets are sometimes manufactured in pairs by the face to face method.Instead of forming loops over a wire and then cutting the loops, the

and forwards between the two carpet foundations The two carpets thusformed are separated in the loom as they are' formed by cutting mechanism which severs the pile threads midway be tween the foundations. InFig. '1 some of the pileforming warp threads a at the left hand side ofthe figure are shown severed medially allowing the threads to open outinto tufts as shown at e This method of manufacture has certainadvantages in, that, when working a pattern in several colors,thecolo'rsnot actually hein'glused'for the pile formation can be dividedbetween the two carpet foundations. The two carpets, when finished,would appear to be identical to look at, but, if complementary areas oftheir foundations were examined, it would be found that only some of the'color threads were carried through in the foundation of one carpetwhilst the remaining color threadswould only be found in the foundatioiiofthe'coinplenientary carpet, and vice versa. This construction enableseconomy to be effected in the pile yarn, but the lo om for carrying outthis method is more complicated.

' However, this method can usefully be employed in carrying out thepresent invention and it. will be seen in Fig. 7.: that the pile-formingwarp threads a and a alternately zigzag between 'the' foundations of thetwo carpets and are combined threads being carried in"each foundationalter-' nately.

It will be noted also that in the channels ,1

' thewarp threads 'a arein the foundation of the upper carpet and'thewarp threads a 'are in th'e' foundation of the'lower carpet." Thisarrangement ofthe pile-forming yarn is done in order 'tobalance"the'tw'o 'ca'rpets as' nearly as possible butit has'one' small disadvantage, namely, that in each carpet at the 'borders of thepilebare'ai'ea f th'e inter-stice at one border has only o'n'e'pilethread-drawn through itwhilst" at theother border the intersti ce hasthree pile threadsthr'ough it; In effect, therefore, the carpet shown inFig. -B-has 'four' densi-' ties of tufted areas inaddition to thepile-bare areas." In'other words'tliere' 'are'the normal pile areaswithtwo 'pile' threads through each interstice, two denserthan normalpile'areas, i. eI, a much dens'ef'tliafi normal pile area in which thereare four pile threads through each inter stice and a" slightly denserthan normal pile areain which thereareonly three pile threads in'eachinterstice and'finally a'less dense than normal pile 'a'rea in' whichthere is only one,

thread in eachinterstice. Theproduction of the slightly de'nse r thannormalfpile area and the lessdense than normal pile area is only theresult of attempting to make thetwo carpets substantially equal inweight and quality of foundation. It woii1d be" perfectly" simple tocarry b'oth'fthe -pile -fo rn 1 ihg"threadsn and a'f: through, the onefoundation and the result would then'be that the p ile bare areas fwould be bordered atone side-by interstices having ,four

pile threads through ,each,interstice whilst the other edge would .beborderedbya single. row of intersices having two'pile threads throughthem,

i. e., as in a normal density pile area but this would not matter sincethe next row of intere warmer;

'The accompanying drawings show a two-shot stices' would be ofinterstices having four pile weft, but our invention isequally'applicable to a three-shot weft. v

, It will also be understood that the pile-forming warp threads a a aand a may be trebled instead of doubled, and the doubled or trebledthreads can be extended to any number of interstices on either or oneach side of the channels F, the number of double or treble threadsbeing determined by the depth of the pile and/or by the type of design.

While we have shown and described several embodiments of our invention,it is to be understood that we do not wish to be limited to the specificmethod and means described since other means may be employed foraccomplishin the same desired ends without departing from the spirit ofthe invention as defined in the appended claims.

What we claim is:

1. In the method of weaving a patterned pile carpet in which the pile isproduced by drawing threads of pile-forming warp yarn through theinterstices formed between adjacent pairs of chain warp threads andadjacent weft threads constituting the upper surface of the carpetfoundation, which pile threads are subsequently cut to form the pile,the steps which comprise forming the pattern by providing the uppersurface of the carpet foundation with normal pile areas, pile-bare areasand denser than normal pile areas, and positioning the denser thannormal pile areas along at least part of the .bound' ary of a pile-barearea and between the pilebare area and a normal pile area, said denserthan normal pile area being formed by drawing a thicker mass of threadsof pile-forming warp yarn through each interstice of said denser pilearea than is drawn through each interstice of a normal pile area.

2. In the method of weaving a' patterned pile carpet in which the pileis produced by drawing threads of pile-forming warp yarn through theinterstices formed between adjacent pairs of chain warp threads andadjacent weft threads constituting the upper surface of the carpetfoundation, which pile threads are subsequently cut to form the pile,the steps which comprise forming the pattern by providing the uppersurface of the carpet foundation with normal pile areas, pile-bare areasand denser than normal pile areas, and positioning the denser thannormal pile areas along at least part of the boundary of a pile-barearea and between the pilebare area and a normal pile area, said denserthan normal pile area being formed by drawing a greater number of pilethreads through each interstice of said denser pile area than is drawnthrough each interstice of a normal pile area.

3. In the method of weaving a patterned pile carpet in which the pile isproduced by drawing loops of pile-forming warp yarn through theinterstices formed between adjacent pairs of chain warp threads andadjacent weft threads constituting the upper surface of the carpetfoundation, which pile loops are subsequently cut to form the pile, thesteps which comprise forming the pattern by providing the upper surfaceof the carpet foundation with normal pile areas, pile-bare areas anddenser than normal pile areas, and positioning the denser than normalpile-areas along at least part of the boundaries of a pile-bare area andbetween the pile-bare area and a normal pile area, said denser thannormal 'pile area being formed by drawing a thicker mass of loops ofpile-forming warp yarn through each interstice of said denser pile areathan is drawn through each interstice of a normal pile area.

4. In the method of weaving a patterned pilecarpet in which the pile isproduced by draw-- ing loops ofpile-forming warp yarn through theinterstices formed between adjacent pairs of chain warp threads andadjacent weft threads constituting the upper surface of the carpetfoundation, which pile loops are subsequently cut to form the pile, thesteps which comprise forming the pattern by providing the upper surfaceof the carpet foundation with normal pile areas, pile-bare areas anddenser than normal pile areas, and positioning the denser than normalpile areas along at least part of the boundaries of a pile-bare area andbetween the pilebare area and a normal pile area, said denser thannormal pile area being formed by drawing a greater number of pile loopsthrough each interstice of said denser pile area than is drawn througheach interstice of a normal pile area.

5. In the method of weaving a patterned pile carpet in which the pile isproduced by drawing pile-forming warp yarn through the inter-- sticesformed between adjacent pairs of chain warp threads and adjacent weftthreads constituting the upper surface of the carpet foundation, thesteps which comprise forming the pattern by providing the upper surfaceof the foundation with normal pile areas, pile-bare areas. and denserthan normal pile areas, and positioning the denser than normal pile areaalong at least part of the boundary of a pile-bare area and between thepile-bare area and a normal pile area, said denser than normal pile areacovering at least two rows of interstices and being formed by drawing athicker mass of pileforming warp yarn through each interstice of saidrows than is drawn through each interstice of a normal pile area.

6. In the method of weaving a patterned pile carpet in which the pile isproduced by drawing threads of pile-forming warp yarn through theinterstices formed between adjacent pairs of chain warp threads andadjacent weft threads constituting the upper surface of the carpetfoundation, which pile threads are subsequently cut to form the pile,the steps which comprise forming the pattern by providing the uppersurface of the carpet foundation with normal pile areas, channel shapedpile-bare areas and denser than normal pile areas, and positioning thedenser than normal pile area along both boundaries of the channelbetween the pile-bare area and a normal pile area, said denser thannormal pile area being formed by drawing a thicker mass of threads ofpile-forming warp yarn through each interstice of said denser pile areathan is drawn through each interstice of a normal pile area.

1 '7. In the method of weaving a patterned pile carpet in which twopile-forming warp yarns are usedand in which the pile is produced bydrawing loops of pile-forming warp yarn through the interstices formedbetween adjacent pairs of chain warp threads and adjacent weft threadsconstituting the upper surface of the carpet foundation, which pileloops are subsequently cut to form the pile, the steps which compriseforming the patern by providing the upper surface of the carpetfoundation with normal pile areas by drawing up a loop of one of thepile-forming constituting the uppersurface ofthe carpet foundation,which pileloops are subsequently out to -formthe pile; the stepswhichcomprisef-forming -the pattern by providing the upper surf-aceofthe carpet foundation with normal pileareas by drawing up aloop of thesame pile-forming' warp yarns through each inters'tice,piIe-bare'area's; and 'dense1'- than normal pile areas by drawing upaloop of both pile-forming warp yarns through each-interstice,andposit'ioning the denser than normal: pile areas along atleast 'part'of the boundary of a pile-bare area and between the pile-bare areavand anormal pile area.

i 9-.ilI-n the method of'weavinga patterned pile carpet in which twopile-forming warp yarns are usedand in which-the pile is producedbydra'wingloops of pile-'forming'warp'yarn through the" intersticesformed between adjacent pairs of chain'warp threads and adjacentweftthreads constituting: the upper-S surface of the carpetfoundation,.which pile loops are subsequentlycut-to form the'pile, thestepswhich comprise forming the pattern by-prcviding 'the up'p'ersurface ofthe carpet fcundationuwitha normal pileareas-by drawingupaloop of alternate'pileforming warp yarns through each alternateinterstice, pile-bare areas and denser than normal pilesareas-by drawingup. a loop of both pile forming warp yarns through ea'ch interstice, andpositioning. the denser than normal'pile areas along at least part ofthe boundary of a pile-bare area and between the pile-bare area and anormal pile area- 10: In the method of weaving. carpets by thedouble-cloth method employing two sets'of weit' threads,- twosets ofstuffer warp threads and two sets of chain warp threads, thus formingtheb'ases' for two carpets, passing one pile warp thread throughselected interstices in each base to formnormal pile. areas, leavingother selected interstices blank so as to form pile-bare area channelsin the pile, passing a second Warp thread throughthe interstices betweensaid channels and-a normal pile area to form a denser than normal pile"area, and separating the two carpets thus formed by cutting the pilewarp threads.-

11. In the method 'of claim 10 wherein onepile' warp thread is utilizedtoform-the normal pile area on one side of a channel and the secondwarp'thread forms 'the normal pilearea On-the other side of the channel.

12. A carpet having a foundation of Weft threads, stufier warp threadsandchain warp threads and apile for med by pile threadspassing throughinterstices in the" foundation between said weft threads, the density ofthe pile being varied so that in some areas .theinterstices havefour'pil'e threads passing through, in other areas the interstices haveonlytwo ipile threads passing through and in still furtherareastheinterstices have no pilethreads passing throughyaand :inrespeet--to"'such lastmentioned 'areas only one pile forming thread iscarried through'the' foun'tiation withthe stufier warp threads; eacharea through the interstices of whichno pile threads pass having-alongat least a part of-its boundaryan'd be tween: it and an area through theinterstices of which twopile threads pass, a denser area throughtheinterstices of which fourpile' threads pass 13. A patterned pilecarpetco'mprising a carpet foundation having interstices formed by chainwarp-threads and weftthreads, and apatterned pile formed by pile-formingwarp yarn passing through interstices" in the foundation an'dprov'idingnormal pile'areas', pile*bare areas; and denser'thannormal pile areas,each pile-bare area having atleast along-part of its boundary acomplemental pile area denser thananadjacent pile area furtherremoved-from-s'aid pilebare area,- said denser pile areabeing providedby a-thickermass'of pile-forming yarn passingthrougheach interstice ofsaid denser pile area than through each intersticeof anormal pile area.

I 14. A patterned pile carpet-comprising a carpet foundation havinginterstices formed by chain warp threads and weftthreads, and apatterned pile formed by threads of pile-forming warp yarn passingthrough interstices in-the founda-" t'ion and provid-ing normal pilearea's, pile-bare areas, and denser than normal pile areas, eachpile-bare area having at least along apart of its boundary acomplemental; pile area denser than anatijacent 'pile area furtherremoved from said pile-bare area, saiddnser pile areabeing provided by agreater number of pile-formingthreads of yarn passing through eachinterstice ofsaid denser pilar'ea than through'each inters'ticeofanormal pile area.

15. A patterned pile carpet comprising a carpet foundation havinginterstices and a patterned pile having normal pile areas, pile-bareareas and denser than normal 'pile areas, the denser than normal pileareas forming a complemental bol lflda'lyffo hat least part ofapile-bare area and being: disposed between the pile bare area andanormal pile area farther removed from said pile '-ba'r'e area.

l6. Apatte'rned p'ile'carpet according to claim 15' Where'in'the denserthan normal pile areas are provided by thicker masses of pile-formingyarn extending through each interstice of the carpet foundation atsaid'd'nser than normal pile areas than throu'gh'each' 'inters tice ofthe carpet foundation at the normal pile areas. H

17. A patterned pile carpet according to claim 16*wherein'the'denserthan normal pile 'area is provided by'a thicker massof pile-forming yarnextending'through at least two rows "of interstices adjacent bothmargins of each of said pile-bare areas.- I

LAURENCE -HUGH 'MACKAY. JOHN MACKAY.

REFERENCES CITED The following references are of record in the fileofthispatent:

UNITED STATES PATENTS

